- Work Orders and Build Tracker8
- Non-Conformance Register8
- Safety Incident and Hazard Register8
- Plant Maintenance and Calibration Requests8
Built precisely, assembled proudly
CAQA Nexus Automotive Manufacturing designs and builds truck bodies, semi-trailers and bus bodies on customer supplied and dealer supplied chassis, and manufactures the component kits that go into them.
CAQA Nexus Automotive Manufacturing, automotive component and vehicle body manufacturing
CAQA Nexus Automotive Manufacturing designs and builds truck bodies, semi-trailers and bus bodies on customer supplied and dealer supplied chassis, and manufactures the component kits that go into them. The product range covers steel and aluminium tipper bodies, pantech and refrigerated van bodies, curtainsiders, flat top and drop deck semi-trailers, and route and school bus bodies. The component workshop produces hydraulic tipping kits, brake and air kits, fibreglass mouldings and wiring looms for the company's own builds and for other body builders. Customers are transport operators, fleet owners, dealers, councils and bus operators across the eastern states.
The business operates from three sites. The Wacol plant in Queensland holds the fabrication and welding shop, the component workshop, the chassis and frame assembly hall, the body build and fit-out line, the paint shop and the final inspection bay. The Wetherill Park plant in New South Wales assembles and fits out semi-trailers and provides a second paint line. The Derrimut centre in Victoria carries out warranty repairs, servicing and minor modifications. Production runs a day shift from 6:30 am with a second shift on the fit-out line during peak periods, and every build travels on a work order that records each stage from cut list to delivery.
Precision
Measure twice, cut once. Every part is made to the drawing and every deviation is recorded, never hidden.
Safety first
Nobody goes home hurt. Hot work, lifting and paint operations run to the procedure every time, whatever the delivery date.
Compliance without compromise
A vehicle leaves the plant only when it meets every applicable Australian Design Rule and the customer's specification.
Team craft
We train apprentices properly, share skills between trades and improve the way we work every week.
Services and operations
To build heavy vehicle bodies, trailers and components that are safe, compliant and precisely made, delivered when we promised them.
Truck body manufacture
Design and manufacture of steel and aluminium tipper bodies, pantech and refrigerated van bodies, curtainsiders and service bodies fitted to customer or dealer supplied cab chassis.
Semi-trailer manufacture
Flat top, drop deck and extendable semi-trailers built at Wetherill Park with certified axle groups, suspension, braking and lighting to heavy vehicle standards.
Bus body building
Route and school bus bodies built on chassis from major manufacturers, including framing, glazing, seating, air conditioning and electrical fit-out.
Component kits
Hydraulic tipping kits, brake and air kits, wiring looms and fibreglass mouldings manufactured for Nexus builds and supplied to other body builders.
Modifications and certification
Wheelbase changes, tow couplings, additional axles and other modifications engineered and certified under the national code of practice for heavy vehicle modifications.
Service and warranty
Post-delivery servicing, warranty repairs, paint rework and customer support from the Derrimut centre and by mobile technicians on the east coast.
Six departments, one workplace
Each department has a purpose, a lead, responsibilities, performance measures and the systems it works in. Students are placed in a department by their scenario.
Fabrication and Welding
Cuts, folds, machines and welds the steel and aluminium sections that become chassis rails, subframes, trailer frames, body frames...
Visit departmentChassis and Frame Assembly
Builds up frames and chassis into rolling assemblies by fitting axle groups, suspension, brake and air kits, hydraulic kits, landi...
Visit departmentBody Build and Fit-out
Builds body panels, floors, doors and roofs onto frames, bonds and repairs fibreglass components, installs glass, trim, seating, l...
Visit departmentPaint and Finishing
Prepares, primes, paints and finishes chassis, bodies and panels in two spray booths, reworks paint faults and applies decals and ...
Visit departmentQuality and Compliance
Owns the quality management system, drawing control, calibration, inspection and test plans, non-conformance management and the co...
Visit departmentProduction Planning and Support
Schedules builds across the three sites, raises and releases work orders, runs the stores and purchasing function, maintains plant...
Visit departmentWorking systems with real records
Every system is live in your browser: create, update, search, move cards on a board and export what you did. Reset returns the seed data at any time.
Work Orders and Build Tracker
Tracks every body, trailer and bus build from planned release through fabrication, assembly, fit-out, paint and final inspection to delivery.
8 recordsNon-Conformance Register
Records every product, material or process non-conformance found at stage gates, in the field or at supplier receival, with disposition and corrective action status.
8 recordsSafety Incident and Hazard Register
The register of injuries, near misses, hazards, chemical exposures and property damage across the three sites, with investigation status and actions.
8 recordsPlant Maintenance and Calibration Requests
Logs breakdown, preventive service, calibration and inspection requests for cranes, machines, welding equipment, booths and measuring equipment.
8 recordsMaterials and Components Stock
Stores register of steel, sheet, fasteners, hydraulic, electrical and paint stock with quantities on hand, reorder points and supplier.
8 recordsInbox
8 work requests from managers and colleagues, each linked to a scenario or a document.
Open inboxEight workplace scenarios
Sign in as a role, read the brief, work through the tasks using the documents and systems, then print an evidence summary for your assessor.
Prepare materials for a tipper subframe using the jig
You are a production worker in the fabrication shop.
Open scenario Intermediate 3 to 4 hoursWeld replacement trailer cross members with gas metal arc welding
You are a welder in the trailer frame bay.
Open scenario Intermediate 3 to 4 hoursAssemble, install and test a hydraulic tipping kit
You are a technical operator in the chassis and frame assembly hall.
Open scenario Entry 2 to 3 hoursFit out a pantech body: door, floor and trim
You are a production worker on the body build and fit-out line.
Open scenario Intermediate 3 to 4 hoursDiagnose, repair and test the trailer and body lighting circuit
You are an auto electrical technical operator on the fit-out line.
Open scenario Intermediate 3 to 4 hoursIdentify and rework paint faults on a curtainsider bulkhead
You are a vehicle painter in the paint shop.
Open scenario Advanced 4 to 5 hoursFinal inspection and pre-delivery of a drop deck semi-trailer
You are a quality inspector in the final inspection bay.
Open scenario Advanced 4 to 5 hoursLead a productivity improvement project on the fit-out line
You are a leading hand seconded to lead the fit-out line improvement project.
Open scenarioNotice board All notices
- Safety Arc flash injury: screens must stay fixed
3 September 2026 - Quality Drawing revision control: check before you cut
8 September 2026 - Safety Isocyanate health monitoring
9 September 2026
Coming up Calendar
- 14/09Daily production meeting
6:45 am, Production office, Wacol - 15/09Weighbridge and road test, WO-26-0420
9:00 am, Final inspection yard, Wacol - 17/09Safety committee meeting
1:00 pm, Training room, Wacol - 18/09Delivery of drop deck semi-trailer to Northgate Truck Centre
10:00 am, Final inspection yard, Wacol
Mapped to the Automotive Manufacturing
Every scenario lists the current units of competency and qualifications it supports, with assessor notes and a printable evidence summary. Use it with your own assessment tools or ask CAQA for a matched kit.